Cycloalkane epoxides produced by air oxidation of cycloalkenes

ABSTRACT

A process for the production of cycloalkane epoxides from cycloalkenes in the presence of a boron-containing catalyst, oxygen and a carboxylate ion source via air oxidation is described. Alkali metal borates, alkali earth metal borates, rare earth borates and transition metal borates are useful catalysts. The boron catalyst may contain many different cations including lithium, sodium, strontium, barium, cerium, zirconium, vanadium, niobium, iron, cobalt, nickel, copper, zinc, and mixtures thereof. The reaction is conducted at a temperature in the range of 50° to 150° C. and a pressure of one atmosphere or greater. Cycloalkane epoxides are useful in the preparation of resins, plasticizers, etc.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is related to a process for the production of cycloalkane epoxides by the air oxidation of cycloalkenes, and is particularly related to such a process conducted in the presence of a boron-containing catalyst.

2. Description of Relevant Methods

The production of ethylene oxide from ethylene has long been known. However, there has been a less successful search for a similar process for producing other oxides directly from olefins in an economic manner. The same processes which produced ethylene oxide cannot be adapted to the production of other oxides.

As a result, a number of different schemes to produce olefin oxides from olefins or to produce an intermediate to olefin oxides from olefins have been proposed. One segment of the research effort seemed to be directed to producing an olefin oxide directly from the olefin in the presence or absence of a solvent. U.S. Pat. No. 2,649,463 describes the production of a coordination complex created by the reaction of an olefin with a metal halide where the metal is copper, platinum, palladium, iridium, aluminum, zinc, silver, mercury or antimony. This coordination complex is further reacted with oxygen at a high temperature to produce the olefin oxide plus oxygen-containing metal halides. Hawkins, et al. in an article entitled, "Autoxidation of Olefins," in the Journal of Applied Chemistry, Vol. 6, 1956, pgs 1 through 10, describes a process for the production of epoxides directly from olefins and molecular oxygen over magnesium oxide and/or cobalt naphthenate. The direct production of olefin oxides from a mono olefin and a saturated hydrooarbon with oxygen and water, organic acids or olefin oxide in low concentration is described in U.S. Pat. No. 2,780,634.

Brill, et al. in Journal of Organic Chemistry, Vol. 29, 1964, pgs 140-143, describes a process for passing olefins and oxygen, frequently in contact with or dissolved in benzene over various catalysts such as azobisisobutyronitrile, cadmium oxide, cobaltic acetylacetonate, magnesium oxide or methyl ethyl ketone peroxide to produce various oxidation products, including the desired epoxides. U.S. Pat. No. 3,132,156 reveals that ethylene, propylene or butylene oxide may be produced directly from ethane, propane or butane under very precise conditions. These conditions include a temperature of between 425° to 575° C., an oxygen volume percent of between 4 and 14, a contact time with the oxygen of between 0.07-1.5 seconds, a pressure of between 20 to 150 psig and constant concentrations of reactants. Epoxides may also be produced from olefins and oxygen which are in an inert reaction medium when they are brought in contact with a rhenium catalyst and 0.05 to 15 weight percent of a reaction modifier comprised of an alkyl aryl or cyclo alkyl cyanide, pyridine or quinoline in accordance with the invention described in U.S. Pat. No. 3,316,279.

Other schemes for producing olefin oxides from olefins and oxygen by means of a solvent or liquid reaction medium include the following. U.S. Pat. No. 3,153,058 employs polyacyl esters of polyhydroxy alkanes, polyhydroxy cycloalkanes, polyglycols or mixtures thereof as the solvent. Materials selected from saturated aliphatic, alicyclic and aromatic nitriles and mixtures thereof form the solvent in U.S. Pat. No. 3,210,180. Boric acid esters form the liquid reaction medium in U.S. Pat. No. 3,210,381. U.S. Pat. No. 3,228,967 uses major amounts of acetone as the solvent. Carbonic acid esters are employed in U.S. Pat. No. 3,228,968, and at least 25 percent by weight of certain ketones serves as the reaction medium in U.S. Pat. No. 3,232,957. Halogenated benzenes serve as the solvent in U.S. Pat. No. 3,238,229 while benzoic acid esters are employed in a similar reaction described in U.S. Pat. No. 3,281,433. Olefin oxides may be prepared directly from olefins and oxygen over a hydrocarbon soluble, phosphorous molybdenum-hydroxy compound catalyst according to the disclosure in U.S. Pat. No. 3,856,826. The approach of making epoxides directly has never been commercially feasible because all of the methods explored gave low yields of epoxides.

Some of the more recent patents in this field include the following methods to make glycol esters which are precursors to the epoxides. Esters may be produced from olefins in an acid plus oxygen over a tin or cerium catalyst in the presence of iodide as revealed by U.S. Pat. No. 4,154,957. Saturated vicinal esters may be produced from olefins, carboxylic acids and oxygen in the presence of a boron-containing catalyst according to the invention of U.S. Pat. No. 4,220,800. U.S. Pat. No. 4,221,916 teaches that olefins, carboxylic acids and oxygen when reacted together over a vanadium or ruthenium-containing catalyst can also produce saturated vicinal esters. U.S. Pat. No. 4,238,624 discloses a procedure by which ethylene, oxygen and a lower alkanoic acid are reacted together over an iodine source in a bismuth stabilized tellurium oxide catalyst on a carbon support to give ethylene glycol mono-and dialkanoates. U.S. Pat. No. 4,069,381 reveals how glycol monoesters may be made from olefins, oxygen and carboxylic acids over a catalyst system where the cation is zirconium, niobium, molybdenum, hafnium, tantalum, tungsten or rhenium where the anion is a halide in the presence of lithium, sodium, potassium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, aluminum or silver.

Methods also exist for converting the ester intermediates into the epoxides. For example, U.S. Pat. No. 4,012,423 describes how vicinal hydroxy esters may be reacted over group I, II and IIIA basic metal carboxylates, being the preferred catalyst (sodium, potassium, lithium, calcium or barium, etc.), or group I, II and IIIA basic metal simple oxides and complex oxides and organic bases (such as borates, phosphates, oxides and carboxylates, particularly sodium borate, nickel oxide, etc.) to give epoxides. Another method is described in U.S. Pat. No. 4,158,008 whereby propylene glycol monoesters in the presence of a high boiling solvent is reacted over a base to produce propylene oxide. Propylene oxide may also be produced from propylene glycol with the removal of a water molecule over a weakly acidic carrier comprising a basic alkali metal salt of a low molecular weight carboxylic acid as taught by U.S. Pat. No. 4,226,780.

Cycloalkenes are also known to be oxidized. Boron-containing catalysts, in the form of boric acid, boric oxide and boron trialkoxy compounds, are also used in the oxidation of 1,5,9-cyclododecatriene according to Japanese Pat. No. 73-21,936 (Chemical Abstracts 79:104812p). Cyclooctene was oxidized with air at 110° C. for twelve hours in the presence of cobalt naphthenate to give 22% conversion, 56% selectivity to epoxide and 14% selectivity to alcohol plus ketone, according to German Offenlegungsschrift 923,185 (CA 52:4685).

European patent application No. 31,537 teaches epoxide production from olefins, including cycloalkenes, and hydrogen peroxide in an anhydrous solvent containing boron catalysts, such as orthoboric acid. The epoxidation of cyclododecene with performic acid formed in situ is described in European patent application No. 34,206. Methods for the direct oxidation of olefins, including cycloalkenes, in the liquid phase by reacting the olefin with hydrogen peroxide in the presence of a boron-containing catalyst; e.g., boron oxides, boron oxyacids, boron halides and the like, are described in U.S. Pat. Nos. 4,303,586 and 4,303,587. Finally, the liquid phase oxidation of high molecular weight alpha olefins gave poor yields to the epoxides according to C. J. Norton, et al. in Oxidation of Organic Compounds, Vol. I, Advances in Chemistry Series 75, American Chemical Society, Washington, 1968, p. 89, et seq.

U.S. Pat. No. 3,014,928 teaches that the monoepoxide of cyclododecatriene may be formed by the reaction of cyclododecatriene with various per compounds such as monoperacetate, performic acid, perbenzoic acid and peracetic acid in over 90% yields.

Besides the documents discussed in the three preceding paragraphs, the disclosures considered to be most relevant to the invention at issue are U.S. Pat. Nos. 4,012,423; 4,069,381 and 4,220,800, all of which have been discussed.

Despite all of the investigative routes described so far and the ones that have been devised which have not been described, there is still a need for an efficient method for making cycloalkylene oxides from cyclic olefins, which does not involve a highly corrosive or highly expensive catalyst system.

SUMMARY OF THE INVENTION

The invention concerns a process for the production of cycloalkane epoxides comprising reacting a cycloalkene with oxygen under epoxidation conditions in the presence of a boron-containing catalyst containing a cation selected from the group consisting of an alkali metal, an alkali earth metal, a transition metal and a rare earth or mixtures of such catalysts.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Cycloalkane epoxides, also called cycloalkene oxides may be prepared by the oxygen or air oxidation of olefins in a solvent which is a carboxylate ion source in the presence of at least one of a number of catalysts. The epoxides are useful as intermediates for the preparation of resins, plasticizers and other useful products.

According to the method of this invention, the useful feedstocks are cycloalkenes, or cyclic olefins, having at least one double bond located anywhere within the molecule. It is anticipated that mixtures of olefins may also be used. Specific examples of suitable feedstocks include, but are not limited by, the following list: cyclohexene, cyclooctene, cyclodecene, cyclododecene, etc. and mixtures thereof. Preferably, the olefin has 5 to 16 carbon atoms. Cyclic olefins with two, three and more double bonds are also permitted.

When other alkenes (for example linear n-alkenes) are air oxidized in a carboxylic acid solvent, the main products are the various corresponding glycol esters. In contrast to the prior art, it is possible using conditions given in this invention (with certain cycloalkenes) to obtain the epoxide as the main product.

Of course, molecular oxygen in a pure form or in air is an essential co-reactant for the method of this invention.

The material which may be used as a solvent should be capable of generating a carboxylate ion when it serves as a solvent. These compounds may be generally described as carboxylic acids and anhydrides. They may include materials such as acetic acid, acetic anhydride, various carboxylic acids, etc., although acetic acid and acetic anhydride are the preferred solvents. Acetic anhydride and acetic acid may be used either separately or together. Some borate catalysts work well with one and not the other.

Borate and boride compounds are believed novel for the catalysts of cyclic olefins to cyclic epoxides, never having been previously discovered. Preferred boron compounds include alkali metal borates, alkali earth metal borates, rare earth borides, transition metal borates and transition metal borides, as well as mixtures thereof. Transition metals are defined as those of Groups IIIB, IVB, VB, VIB, VIIB, VIII, IB and IIB, including lanthanides and actinides, of the Periodic Table while alkali metals are those from Group IA and alkali earth metals are from Group IIA. Especially preferred borates and borides include boron compounds where the metal cation is taken from the group consisting of lithium, sodium, strontium, barium, cerium, zirconium, vanadium, niobium, iron, cobalt, nickel, zinc and mixtures thereof.

While all the catalysts of this invention give good results, which may be arbitrarily defined as a vapor phase chromatography area percent yield of 50% or more, some of the catalysts are more preferred than others.

The catalysts of this invention are much less corrosive than many of those used in other methods, especially the halide systems. Also, much smaller catalyst levels may be used. They are also less expensive than many of the catalyst systems proposed.

The reaction conditions under which the method of this invention may be conducted include a temperature range of from about 50° to 250° C. A preferred range is from 50° to 150° C. The pressure may be one atmosphere or higher. These reaction conditions are much milder than many of those in the prior art discussed earlier. The reaction may be performed in a batch or a continuous mode.

Common by-products of the instant reaction include the cycloalkane 1,2-diol (diacetate) or the cycloalkane hydroxyacetate. The hydroxyacetate may be pyrolyzed to the epoxide in the presence of a basic material such as sodium acetate at 250°-600° C. according to British Pat. No. 1,446,395. The diacetate may be converted to the epoxide by a similar route if the diacetate is first hydrolyzed to the hydroxyacetate. Therefore, the diacetate and the hydroxyacetate by-products are also valuable and may be considered as intermediates to the epoxides.

The invention may be further illustrated by the following examples which are not intended to limit the scope of the invention.

EXAMPLES 1-5

Examples 1-5 employ nickel borate in the production of cyclooctane epoxide. All examples followed the procedure described below, with details and the results of the experiments being outlined in Table I.

A resin flask was fitted with a condenser, a mechanical stirrer, a fritted glass addition tube and a thermometer. The reactants and catalysts shown in Table I were charged, the reaction mixture heated to the required temperature and air bubbled through the reaction mixture for the desired length of time. The temperature was maintained by means of a Therm-O-Watch temperature regulator. At the end of the reaction, the mixture was cooled to room temperature and poured into an equal volume of water. The mixture was shaken or stirred until all of the anhydride had dissolved (hydrolyzed). The organic layer was washed twice more with an equal volume of water and dried over anhydrous sodium sulfate. The products were determined (for the most part) by nuclear magnetic resonance.

                                      TABLE I                                      __________________________________________________________________________                                        Products.sup.2                                                                           Cyclo-                                 Cyclo-                             Cyclo-                                                                              octane                                 octene                                                                             Acetic                                                                             Acetic                                                                               Nickel     Flow Cyclo-                                                                              octene                                                                              1,2-diol                               tech.,.sup.1                                                                       Acid,                                                                              Anhydride,                                                                           Borate,                                                                            Time,                                                                             Temp.,                                                                             Rate,                                                                               octene,                                                                             Epoxide,                                                                            (diacetate)                       Example                                                                             ml  ml  ml    g   Hour                                                                              °C.                                                                         (ml/min)                                                                            mole %                                                                              mole %                                                                              mole %                            __________________________________________________________________________     1    25.0                                                                               --  50    0.033                                                                              7.5                                                                               110 50-60                                                                               54.8 32.3 Small amount                      2    20.0                                                                               --  50    0.026                                                                              5.5                                                                               110 60-70                                                                               ˜85.sup.3                                                                     ˜13.sup.3                                                                     Small amount                      3    30.0                                                                               --  90    0.036                                                                              24 110 40-45                                                                               33   9    47                                4    30.0                                                                                50 50    0.043                                                                              26 110 40-45                                                                               67   n.d..sup.4                                                                          33                                5    30.0                                                                               100 --    0.039                                                                              13 100 40-50                                                                               No significant reaction                     __________________________________________________________________________      .sup.1 Cyclooctene is manufactured by Aldrich Chemical Co., Inc. 95%           purity used "as is"-                                                           .sup.2 Products determined by NMR analysis of reaction mixtures                .sup.3 By IR analysis                                                          .sup.4 n.d. = none detected                                              

Examples 4 and 5, which employed acetic acid in the reactant mixture, gave no significant reaction. This result indicates that acetic acid may have an inhibiting effect on direct epoxide formation with the nickel borate catalyst. However, the diacetate by-product is also useful and one skilled in the art may prefer to make the diacetate the major product.

EXAMPLES 6-11

Examples 6 through 11 also use nickel borate as a catalyst, but this time in conjunction with cyclododecene. The procedure outlined below was followed in each case with the results shown in Table II.

A resin flask was fitted with a condenser, a mechanical stirrer, a fritted glass addition tube and a thermometer. The reactants, catalyst and solvent shown in Table II were charged and the reaction mixture heated to the desired temperature. Air was bubbled through the reaction mixture for the required length of time. The temperature was maintained by means of a Therm-O-Watch temperature regulator. At the end of the reaction, the mixture was poured into an equal volume of water and shaken (or stirred) until all of the acetic anhydride had hydrolyzed. The organic layer was washed twice more with an equal volume of water and dried over anhydrous sodium sulfate. In some experiments, the organic layer was a viscous oil and had to be taken up in about 100 ml of methylene chloride before the final water washes. The methylene chloride solution was dried over sodium sulfate, filtered, and removed on a rotary evaporator before analysis. The total ester was determined by infrared analysis. The other products were determined by nuclear magnetic resonance.

                                      TABLE II                                     __________________________________________________________________________                                            Products                                                                                          Cyclo-                    Cyclodo-                          Total       Cyclo- dodecane                  decene.sup.1                                                                        Acetic                                                                              Acetic                                                                               Nickel       Flow Ester.sup.2,                                                                        Cyclodo-                                                                              dodecane.sup.3                                                                        1,2-diol.sup.3            tech.,                                                                              Acid,                                                                               Anhydride,                                                                           Borate,                                                                             Time,                                                                              Temp.,                                                                             Rate,                                                                               by IR,                                                                              decene,                                                                               (Epoxide)                                                                             diacetate,           Example                                                                             ml   ml   ml    g    Hour                                                                               °C.                                                                         (ml/min)                                                                            mole %                                                                              mole % mole % mole                 __________________________________________________________________________                                                               %                    6    30.0  30  50    0.034                                                                               24  100 40-45                                                                               42   Small amount                                                                          33     33                   7    30.0 --   100   0.028                                                                               22  110 40-45                                                                               69   --     --     --                   8    30.0 100  --    0.035                                                                               38   95 40-45                                                                                5   --     --     --                   9    30.0 --   90    0.035                                                                               24  110 40-45                                                                               50   Small amount                                                                          Small                                                                                 --ount               10   30.0  50  50    0.048                                                                               26  110 40-45                                                                               54   Small amount                                                                          Small                                                                                 --ount               11   35.0 100  --    0.038                                                                               13.5                                                                               100 40-50                                                                               11   70     20     --                   __________________________________________________________________________                                                               3                     .sup.1 Aldrich technical grade used "as                                        .sup.2 Using ester band at ˜5.75 microns                                 .sup.3 Other products determined by NMR                                  

EXAMPLES 12-29

The remaining examples use a variety of catalysts. Two comparative examples are included. Example 12 uses no catalyst while Example 13 employs boric anhydride as the catalyst as taught by U.S. Pat. No. 4,220,800, previously discussed.

All examples follow the procedure described below and the results are tabulated in Table III.

A small resin flask was fitted with a condenser, a mechanical stirrer, a fritted glass addition tube and a thermometer. Acetic acid (70-100 ml), cyclododecene (20-30 ml) and a catalyst (0.10-0.20 g) were charged to the flask and the mixture heated to 100° C. Air was bubbled through the reaction mixture at 40-50 ml/minute for 15 to 20 hours. The temperature was maintained at 100°±2° C. by means of a Therm-O-Watch temperature regulator. At the end of the reaction, the mixture was poured into water and the aqueous layer drawn off and discarded. The upper layer was washed three times with water, dried over anhydrous sodium sulfate and analyzed by vapor phase chromatography (VPC). The results in terms of area percent from vapor phase chromatography should be used only to compare one example to another. They are not meant to be an absolute measure in terms of, for example, the weight percent of a component in a product stream.

Combination borate catalysts were also found to be useful, as seen in Examples 20, 22 and 23. The dual bariumnickel borate catalyst of Example 20 was prepared by the following procedure.

Sodium borate (20.1 g) was placed in 100 ml of water and warmed until all of the solid had dissolved. Nickel (II) nitrate (7.2 g) and barium chloride (12.2 g) were dissolved in 50 ml of water and added slowly (vigorous stirring) to the sodium borate solution. The mixture was stirred at 60°-70° C. for an hour, cooled to room temperature and the solid collected with suction. The solid was washed with water and dried at 60°-70° C. for 24 hours. Atomic absorption analysis showed the following results: 13.8% B, 6.5% Ni, 29.4% Ba and 2.8% Na.

                                      TABLE III                                    __________________________________________________________________________                     Catalyst,                                                                           Conv.,                                                                             Selectivity, %                                                                              Yield,                                   Example                                                                             Catalyst   g    %   Epoxide                                                                             Esters                                                                             Total                                        __________________________________________________________________________     12   None       --   61.6                                                                               64.4 11.2                                                                               75.6                                                                               46.6                                     13   Boric Anhydride                                                                           0.2  52.5                                                                               70.1 10.1                                                                               80.2                                                                               42.1                                     14   Zirconyl Borate                                                                           0.2  82.5                                                                               63.3 18.8                                                                               82.1                                                                               67.7                                     15   Lithium Borate                                                                            0.2  54.7                                                                               79.2 11.5                                                                               90.7                                                                               49.6                                     16   Barium Metaborate                                                                         0.2  59.7                                                                               70.5 10.6                                                                               81.1                                                                               48.4                                     17   Barium Metaborate                                                                         0.2  61.3                                                                               71.2 13.4                                                                               84.6                                                                               51.9                                     18   Strontium Borate                                                                          0.2  74.0                                                                               68.4 14.9                                                                               83.3                                                                               61.6                                     19   Zinc Borate                                                                               0.2  75.0                                                                               71.6 16.8                                                                               88.4                                                                               66.3                                     20   Barium-Nickel Borate                                                                      0.2  84.7                                                                               65.6 16.1                                                                               81.7                                                                               69.2                                     21   Nickel Borate                                                                             0.2  78.4                                                                               58.8 16.7                                                                               75.5                                                                               59.2                                     22   Zinc Borate                                                                               0.1  69.0                                                                               67.4 12.5                                                                               79.9                                                                               55.1                                          Ferric Borate                                                                             0.1                                                            23   Cupric Borate                                                                             0.1  81.2                                                                               60.8 19.5                                                                               80.3                                                                               65.2                                          Zinc Borate                                                                               0.1                                                            24   Ferric Borate                                                                             0.2  55.1                                                                               73.0 10.9                                                                               83.9                                                                               46.2                                     25   Cupric Borate                                                                             0.2  68.6                                                                               62.2 18.1                                                                               80.3                                                                               55.1                                     26.sup.1                                                                            Lithium Borate                                                                            0.05 61.3                                                                               64.8 14.9                                                                               79.7                                                                               48.9                                     27.sup.2                                                                            Lithium Borate                                                                            0.05 68.1                                                                               63.0 17.1                                                                               80.1                                                                               54.5                                     28.sup.2                                                                            Lithium Borate                                                                            0.1  69.2                                                                               62.3 16.7                                                                               79.0                                                                               54.5                                     29.sup.1                                                                            Lithium Borate                                                                            0.2  59.3                                                                               74.5 9.2 83.7                                                                               49.6                                     30   Sodium Borate                                                                             0.1  70.7                                                                               65.8 13.9                                                                               79.7                                                                               56.3                                     31   Cerium Hexaboride                                                                         0.1  79.9                                                                               57.8 23.2                                                                               81.0                                                                               64.7                                     32   Niobium Boride                                                                            0.1  60.2                                                                               45.7 16.4                                                                               62.1                                                                               37.4                                     __________________________________________________________________________      .sup.1 Five drops of heptaldehyde present as initiator                         .sup.2 Ten drops of heptaldehyde present                                 

It is interesting to note that the area percent selectivity to the epoxide in these examples is quite high even though acetic acid is the only carboxylate ion source employed.

EXAMPLE 33

A small resin flask was fitted with a mechanical stirrer, a water cooled condenser, a thermometer and a fritted glass addition tube. Cyclooctene (15 ml), acetic anhydride (50 ml) and lithium borate (0.20 g) were charged to the flask and the contents heated to 110° C. Air was sparged through the reaction mixture at 50 ml/minute for 7 hours. The temperature was maintained at 110° C.±2° C. by means of a Therm-O-Watch temperature regulator. At the end of the reaction, the mixture was poured into twice the volume of water and stirred or shaken until all of the acetic anhydride had hydrolyzed. The aqueous layer was drawn off and the organic layer washed twice more with an equal volume of water. The mixture was then dried over anhydrous sodium sulfate. An infrared spectrum of the reaction mixture showed only a trace (if any) of ester present. Nuclear magnetic resonance analysis indicated that the ratio of cyclooctene to epoxide was 15.0:1.0. There was no indication of any ester present.

EXAMPLE 34

A small resin flask was equipped with a mechanical stirrer, a water cooled condenser, a thermometer and a fritted glass addition tube. Cyclooctene (20 ml), acetic acid (50 ml), heptaldehyde (2 drops) and lithium borate (0.10 g) were charged to the flask and the contents heated to 100° C. Air was sparged through the reaction mixture at 50 ml/minute for 15 hours. The temperature was maintained at 100°±2° C. by means of a Therm-O-Watch temperature regulator. At the end of the reaction, the mixture was poured into twice the volume of water. The aqueous layer was drawn off and the organic layer washed twice more with an equal volume of water. The mixture was then dried over anhydrous sodium sulfate. An infrared spectrum indicated that only a trace of ester was present. Nuclear magnetic resonance analysis showed the presence of a small amount (less than 5%) of epoxide. The sample was about 95% cyclooctene.

EXAMPLE 35

A small resin flask was fitted with a mechanical stirrer, a water cooled condenser and a fritted glass addition tube. Cyclooctene (20 ml), acetic anhydride (50 ml), heptaldehyde (2 drops) and mixed vanadyl-cobalt borate (0.20 g) were charged to the flask and the mixture heated to 110° C. The temperature was maintained at 110°±2° C. by means of a Therm-O-Watch temperature regulator. Air was sparged through the reaction mixture at 50 ml/minute for 6.5 hours. At the end of the reaction, the mixture was poured into twice the volume of water and stirred or shaken until all of the acetic anhydride had hydrolyzed. The aqueous layer was drawn off and the organic layer washed twice more with an equal volume of water. The mixture was then dried over anhydrous sodium sulfate. An infrared spectrum showed a significant ester band at 5.77 microns (ester C═O). Nuclear magnetic resonance analysis indicated that the ratio of cyclooctene to epoxide was 3.9:1.0.

The unique combination vanadyl-cobalt borate catalyst used in this example was prepared by the following procedure.

Vanadyl sulfate dihydrate (5 g) and cobalt nitrate hexahydrate (7.3 g) were dissolved in the minimum amount of water and then added slowly to sodium borate (20 g) dissolved in 100 ml of hot (approx. 80° C.) water. This mixture was stirred for an additional 30 minutes at 80° C. and then cooled to room temperature. The solid was collected with suction, washed well with water, and dried at 80°-100° C. for several days. AA analysis of the reaction mixture showed 19.3% cobalt, 2.02% vanadium and 13.7% boron.

EXAMPLE 36

A small resin flask was fitted with a condenser, mechanical stirrer, fritted glass addition tube and thermometer. Acetic acid (70 ml), cyclooctene (from Aldrich Chemical Co. in 95% solution, 20 ml) and nickel borate (0.04 g) were charged to the flask. The mixture was heated to 100° C. and air bubbled through the reaction mixture for 13.5 hours at 40-50 ml/minute. The temperature was maintained at 100° C.±2° C. by means of a Therm-O-Watch temperature regulator. At the end of the reaction, the mixture was poured into water and the aqueous layer drawn off and discarded. The organic layer was washed three times with water and dried over anhydrous sodium sulfate. After workup, infrared analysis indicated only a trace of ester. Nuclear magnetic resonance analysis indicated that the reaction mixture was essentially pure starting material.

Many modifications may be made in the method of this invention by those skilled in the art to maximize the yields of the desired epoxides (or acetates, as the case may be) without departing from the spirit and scope of the invention which is defined only by the appended claims. For example, one skilled in the art could determine an exact combination of catalysts, temperatures, feedstocks and modes of addition to optimize the yield of the desired product. 

We claim:
 1. A method for the production of cyclododecane epoxide consisting essentially ofreacting cyclododecene with oxygen in the presence of a boron-containing catalyst selected from the group consisting of lithium borate, sodium borate, strontium borate, barium metaborate, zinc borate, the combination of zinc borate and ferric borate, the combination of barium borate and nickel borate and mixtures thereof in the presence of a carboxylate ion-generating solvent selected from the group consisting of acetic acid, acetic anhydride and mixtures thereof at a temperature in the range of about 50° to 150° C. 